Air Deflector For Packaged Thermal Air Conditioner And Method For Energy Conversation

ABSTRACT

An energy saving device comprising a semi-rigid polycarbonate deflector being a rectangular panel bent into two longitudinal sectors by a lengthwise bend forming an interior angle ranging from one hundred twenty degrees to one-hundred fifty degrees. The bend is designed with an optimum ergonomic angle of the two sectors such as to allow the directing of airflow emanating from the grilles of a Packaged Thermal Air Conditioner (PTAC). Attachment of the deflector to the top surface of the PTAC provides a more efficient and energy-conserving means to direct the flow of cool (or warm) air produced by the PTAC. Environmentally-friendly push-tab fasteners further enhance durability of the attachment of one sector of the deflector to the top surface of the PTAC.

CROSS-REFERENCES TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates to the use of portable air conditioning units typically found in hotel rooms, high-rise apartment buildings, and in window openings in some homes. In particular, a “packaged thermal air conditioner” (often abbreviated PTAC) is a mechanical unit that is a self-contained heating and air conditioning system. Many PTAC's are designed to be installed through a wall, and have vents and heat sinks both inside and outside.

A common problem with PTAC's is that the air flow from the grill and venting of the unit may be partially blocked by nearby heavy curtains which are installed to cover or partially cover a window near the PTAC. The disclosed device is a flexible rectangular panel having a permanent bend running parallel to both its longitudinal sides. The panel is specifically designed for securing to the top surface of a PTAC and thereby controlling the direction of conditioned air emanating from the PTAC. By directing the airflow in a controlled manner, the device enhances the comfort of the occupants of the room in which the PTAC is installed, and further, provides a substantial energy conservation by more efficient use of the conditioned air.

(2) Description of the Related Art, Including Information Disclosed Under 37 CFR 1.97 and 1.98.

The following documents present material and concepts that are similar to the inventive concept disclosed by Applicant.

U.S. Pat. No. 4,944,654 (Jul. 31, 1990) The invention disclosed is a split scroll which diffuses and directs air upwards from the circumference of a forwardly-curved centrifugal fan to a discharge plane to one side of the fan. The scroll has a first monotonically increasing curved wall that extends from a cutoff point near the circumference of the rotor, in the direction of rotation, to the discharge plane. A second monotonically increasing curved wall extends in the opposite direction from the cutoff point up to the discharge plane. The first and second curved walls are mirror images of one another taken at the plane corresponding to the air flow tangent that passes through the cutoff point. A curved cover above the fan at the exit plane blocks line of sight noise from radiating directly from the fan rotor into the work space or living space.

U.S. Pat. No. 5,194,043 (Mar. 16, 1993). Disclosed is an air conditioner having rotatable first and second deflectors provided in an outlet for discharging conditioned air. The first deflector is rotatable about a substantially horizontal axis so as to variably deflect the conditioned air in vertical directions. The second deflector is rotatable so as to block a breadthwise portion of the outlet while forming an air passage in the remainder breadthwise portion of the outlet. The first and second deflectors are rotatable independently of each other.

U.S. Pat. No. 5,647,341 (Jul. 15, 1997) A gas burner for use in gas fireplaces provides a yellow flickering flame such as that seen in a real wood fire while maintaining a low level of carbon monoxide production. The gas burner is simple in design and compact in size and may be used in either direct vent or gravity vent gas fireplaces. An air baffle plate may be affixed to the rear of the gas burner to maintain the critical balance between primary and secondary combustion air when using liquid propane gas.

U.S. Published Patent Application #2012/0118997 A1 (May 17, 2012). Disclosed is a fan diversion structure which is adapted to be disposed on a fan, and the fan diversion structure comprises at least one deflector and at least one connecting part. The deflector, which is adapted to be disposed across front of an air outlet of the fan, is disposed on one side next to a center of the fan and without overlapping the center of the fan, wherein the deflector extends outwardly so as to deflect an airflow to the side direction of the fan. The connecting part is adapted for connecting the deflector to the fan. Thereby the airflow from the fan not only converges in the axial direction, but also moderately extends to the side of the fan so as to increase the blowing angle and enhance convection efficiency around the fan.

U.S. Published Patent Application #2008/0242215 (Oct. 2, 2008); An air supply shutter for ventilating closed buildings includes a marginal frame with interconnected upper, lower and lateral frame members to define a centrally disposed air vent opening having inlet and outlet sides. A shutter flap is pivotally mounted on the frame for rotation about a generally horizontal axis between closed and open positions. A coupler is connected with the shutter flap and configured for engagement with an activator for shifting the shutter flap between the closed and open positions. The upper frame member includes an air guiding wall which is disposed on the outlet side of the air vent opening, faces the air vent opening, and extends upwardly at a predetermined angle to deflect the air flowing through the air vent opening.

U.S. Published Patent Application #2002/0100289 (Aug. 1, 2002) Disclosed is a blower cover and an air conditioner using such blower. A rollable sheet is locked between two side plates by rollable connectors. A belt plate is secured between the side plates to lock the rollable sheet between the side plates. The belt plate also directs air from the blower. The blower cover can easily be assembled at a work site without welding or expert metal working. The blower cover is used in an air conditioner in which air is forced upwards from the blower and the air is directed into a heat exchange unit by one or more air deflectors. Another air deflector directs air coming out of the heat exchanger in an upwardly direction out of the air conditioner and this air deflector also directs any condensate downwards toward a drain system generally located below the heat air conditioner.

Goodman Manufacturing Company, L.P., 7401 Security Way, Houston, Tex., builds a deflector that may be used on commercial heating and air conditioning units. The Goodman deflector is of a different configuration and functions in a substantially different manner than the inventive concept disclosed in this document. These type deflectors are frequently found in Amana air conditioning units.

BRIEF SUMMARY OF THE INVENTION

The present inventive concept is an angled deflector panel which is ergonomically designed with a profile such as to allow the directing of airflow emanating from the fins or grille of a packaged thermal air conditioner (PTAC). Attachment of the deflector to the top surface of the PTAC provides a more efficient means to direct the flow cool (or warm) air produced by the PTAC. There is a variety of standard dimensions to which PTAC's are manufactured. The most common dimensions found in the consumer market include 42×16 inches, 36×15 inches, and 26×14 inches. A primary objective of the inventive concept disclosed is to conserve energy by efficiently directing the flow of air emanating from the PTAC.

BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS

FIG. 1 is a front view of the rear face 4 of the deflector 1, including one of the push-tab fasteners 17.

FIG. 2 is a cutaway view of the deflector 1 of FIG. 3, as seen from section line 1-1.

FIG. 3 is a magnified view of FIG. 4, showing the preferred 140 degree panel angle 8 of the deflector and the relative dimensions of the upper sector 2 and the attaching sector 5.

FIG. 4 presents a view of the deflector 1 installed on the top surface of the front 16 of a PTAC 25 and as would be seen from the rear of the PTAC 25.

FIG. 5 is a head-on view of the deflector 1 just prior to installation of the deflector 1 on the front 16 of a PTAC (not shown).

FIG. 6 is a profile view of the push tab fastener used for securing the deflector 1 to a PTAC.

FIG. 7 is an upward-looking view of the push-tab fastener 17 of FIG. 6.

FIG. 8 is a side view of the push-tab fastener of FIG. 6.

FIG. 9 is an upward-looking view of the push-tab fastener 17 of FIG. 8.

Table of Nomenclature & Part Numbers of Invention  1. Deflector  2. Upper sector  3. Windward face  4. Rear face  5. Attaching sector  6. Outer surface  7. Inner surface  8. Panel angle  9. Bend 10. Front protective cover 11. Rear protective cover 12. First pre-drilled hole 12(a). First aperture 13. Second pre-drilled hole 13(a). Second aperture 14. Third pre-drilled hole 14(a). Third aperture 15. Fourth pre-drilled hole 15(a). Fourth aperture 16. PTAC front 17. Push-tab fastener 18. Crown 19. Head 20. Stem 21. Retainer ribs 22. Cross-retainer ribs 23. Arrowhead 24. Fins 25. PTAC unit

DETAILED DESCRIPTION OF THE INVENTIVE CONCEPT

The objects, features, and advantages of the concept presented in this application are more readily understood when referring to the accompanying drawings. The drawings, totaling nine figures, show the basic components and functions of embodiments and/or methods of use. In the several figures, like reference numbers are used in each figure to correspond to the same component as may be depicted in other figures.

The discussion of the present inventive concept will be initiated beginning with FIG. 1. In FIG. 1, there is illustrated a rear view of the inventive concept, referred to as a deflector 1, further showing the rear face 4 and the edge of the attaching sector 5 of the deflector 1. Included in FIG. 1 is a rendering of one of a plurality of push-tab fasteners 17 which may inserted through pre-drilled holes 12, 13, 14, 15 along the attaching sector 5 of the deflector 1 to provide a secure attachment of the deflector 1 to the front 16 of the frame of a typical PTAC 25. In the preferred embodiment, four pre-drilled holes are arranged at specific intervals along the attaching sector 5 of the deflector, which holes correspond to the particular profile and configuration of the front frame of any one of a variety of brands of PTAC 25 to which the deflector will be attached. There are occasions where the deflector 1 may be supplied to an end user without pre-drilled holes, thereby allowing the user to attach the deflector 1 with fastening means compatible with the PTAC which is installed by the user.

In FIG. 2, a cutaway view of the side profile of the deflector 1 further clarifies the form and relative dimensions of the deflector 1. The section view of FIG. 2 is taken from the perspective of section line 1-1, the section line aligned along the longitudinal axis of the push-tab fastener 17. FIG. 3 presents a magnified view of the cutaway profile displayed in FIG. 2, further showing the presence of a panel bend 9 comprising a preferred 140-degree panel angle 8 of the deflector 1.

On-site operational experience with various fittings and deflector bend angles has shown that the 140-degree panel bend 9 provides the optimum deflection angle to redistribute the airflow being expelled through the grille or fins 24 of a PTAC 25. However, depending on the room sized to be air conditioned and the brand of PTAC utilized, the panel angle 8 may vary in the range of 120 degrees to 150 degrees. As the cool or warm conditioned air is re-directed by the deflector 1, significant energy savings are realized by providing a quicker and more efficient cool-down (or warm-up) of the living space utilized by the occupants of the room containing the PTAC 25. Preliminary estimates from users of the deflector 1 in hotel chains indicates that the energy savings amount to a six percent (6.0%) reduction in energy to condition the air in designated rooms, as compared to the costs incurred before the installation of deflectors 1 in the rooms.

The preferred embodiment of the deflector is constructed from polycarbonate, and in particular, the Lexan® brand of polycarbonate, which is most amenable to sizing the deflector 1 and the shaping of the bend 9 of the device. In viewing FIG. 3, it is noted that dimensions A, B, C, and D, are set out, which represent a variable range of measurements applied to the construction of the deflector 1 with respect to obtaining the most effective profile and fit of each deflector 1 to a specific manufacturer's brand of PTAC. Another factor is the size and contours of the room in which will be placed a PTAC. Generally, using the polycarbonate material, the thickness (dimension C) is optimally set at ⅛ inch, but may be as high as three-eighths inch. The dimension, D, may be manufactured in the range of seventeen and one-quarter inches to forty-two inches.

Again, referring to FIG. 3, the bend 9, which extends along the length of the deflector 1, defines two components of the deflector 1, being an upper sector 2 and an attaching sector 5. As shown in FIG. 3, the upper sector 2 comprises a rear face 4 and a windward face 3. The attaching sector 5 comprises an outer surface 6 and an inner surface 7. The rear face 4 and the outer face 6 of the deflector 1 both manifest a continuous rear protective cover 11, consisting of plasticized material, which is adhesively attached to both the rear face 4 and the outer surface 6. Similarly, the windward face 3 and the inner surface 7 of the deflector 1 both manifest a continuous front protective cover 10 of the same material, which is adhesively attached to both the windward face 3 and the inner surface 7.

During fabrication of the deflector 1, the rear protective cover 11, having been adhesively attached, is then measured and marked with the locations of drill sites for holes 12, 13, 14, 15 along the outer surface 6 and protective rear cover 11 of the attaching sector 5. The markings correspond to the configuration and profile of the specific PTAC 25 to which the deflector 1 is to be attached. Holes are then pre-drilled through the markings on the rear protective cover 11 and through the attaching sector 5.

Turning to FIG. 4, there is illustrated the rear of a PTAC 25 showing the positioning of a deflector 1 having the pre-drilled holes proximate the rear of a PTAC 25. The front 16 of the PTAC 25 must be removed from the PTAC 25 in the first step of installation of the deflector 1.

The general profile of the PTAC 25 is depicted by dashed lines. In FIG. 4, the rear protective cover 11, although indistinguishable in the view, is adhesively in place on the rear face 4 and the outer surface 6 of the deflector 1 as the deflector is placed in position. The four pre-drilled holes shown, 12, 13, 14, 15, are spaced at intervals 30, 31, 32, 33, and 34, which intervals correspond to the most effective locations for attachment of push-tab fasteners 17 through the attaching sector 5 and onto the top surface of the front 16 of the particular PTAC 25 being worked on. It is to be noted that the spacing intervals 30, 31, 32, 33 will vary in accordance with the specific profile of the grille arrangement of differing brands of PTAC's in the marketplace.

Generally, it is most practical for an installer performing this process to clamp the deflector 1 onto the front 16 of the PTAC 25 in a pre-determined orientation to the surface of the front 16. FIG. 5 more clearly illustrates a typical front cover 16 having been removed from its associated PTAC 25 and the deflector 1 being moved into position to abut the surface of the front 16. Once the clamping process is finished, an electric drill having a bit size corresponding to the four pre-drilled holes 12, 13, 14, 15 is used to axially align with the center of each pre-drilled hole 12, 13, 14, 15 and drill successively at those locations, through the attaching sector 5 and on through the front 16 of the PTAC 25.

Thus there is fabricated a first, second, third, and fourth receptive aperture 12(a), 13(a), 14(a), and 15(a) on the upper front 16 of the PTAC 25. Once the drilling operation is completed, the clamps are released and both protective covers 10, 11, on the deflector 1 are removed from the deflector 1. Next, four push-tab fasteners 17 (not shown) are required to be inserted through the first hole 12, the second hole 13, the third hole 14, and the fourth hole 15, respectively on the outer surface 6 of the attaching sector 5. The deflector 1 is then positioned at the previously determined position on the front 16 and each push-tab fastener 17 is pushed through the corresponding newly-drilled apertures 12(a), 13(a), 14(a), 15(a) in the front 16 by the exercise of moderate finger pressure of the installer. This results in a secure, although not permanent, fit of the deflector 1 onto the front 16 of the PTAC 25. Should an occupant accidentally bump against the deflector 1 and partially dislodge it, it is an easy matter to re-insert the affected push-tab fastener(s) 17 into the specific aperture(s) 12(a), 13(a), 14(a), 15(a).

FIGS. 6, 7, 8, and 9 illustrate the structure of the push-tab fasteners 17, constructed from a semi-rigid plastic type material, which are used to secure the deflector 1 to the front 16 of a PTAC 25. The push-tab fasteners 17 comprise a flat crown 18, a head 19 having a slight downward taper, and a stem 20 from which project a set of vertically-spaced co-planar retainer ribs 21 along the stem 20. An orthogonally-oriented second set of cross-retainer ribs 22 also project along the length of the stem 20. An arrowhead 23 helps guide each push-tab fastener 17 through the pre-drilled holes 12, 13, 14, 15 and continuing on through the apertures 12(a), 13(a), 14(a), and 15(a), thereby providing a secure attachment of the deflector 1. A certain amount of downward fingertip force is applied by the installer against the head 19 of each push-tab fastener 17 into and through the desired pre-drilled holes 12, 13, 14, 1S.

While preferred embodiments of the present inventive concept have been shown and disclosed herein, it will be obvious to those persons skilled in the art that such embodiments are presented by way of example only, and not as a limitation to the scope of the inventive concept. Numerous variations, changes, and substitutions may occur or be suggested to those skilled in the art without departing from the intent, scope, and totality of this inventive concept. Such variations, changes, and substitutions may involve other features which are already known per se and which may be used instead of, in combination with, or in addition to features already disclosed herein. Accordingly, it is intended that this inventive concept be inclusive of such variations, changes, and substitutions, and is by no means limited by the scope of the claims presented herein. 

What is claimed is:
 1. A semi-rigid elastomeric deflector for re-directing the airflow produced by a Packaged Thermal Air Conditioner (PTAC), comprising a substantially longitudinal rectangular of length dimension A, a width dimension of B, and a thickness dimension of C, said panel bent at a straight line parallel to the lengthier sides of said panel, the bend forming an interior angle ranging from one hundred twenty degrees to one hundred fifty degrees, and thereby defining two longitudinally-oriented rectangular sectors, being an upper sector having a windward face and a rear face, and an attaching sector having an upper surface and an inner surface; further, said attaching sector comprising a plurality of linearly-spaced pre-drilled holes arranged at varying intervals along the length, A of said attaching sector so as to provide for the securing of the attaching sector atop the front of the PTAC, said pre-drilled holes of a diameter permitting the insertion of specific multi-ribbed push-tab fasteners of a length enabling the insertion of said push-tab fasteners through said pre-drilled holes and continuing into corresponding apertures drilled in the top surface of any of a variety of specific brand-name PTAC's, said PTAC apertures drilled at intervals corresponding to the intervallic separation of the pre-drilled holes in the attaching sector of the deflector.
 2. A semi-rigid, elastomeric deflector as in claim 1, said deflector constructed of polycarbonate.
 3. A semi-rigid, elastomeric deflector as in claim 1, said deflector constructed of polycarbonate, and further comprising an A dimension of two (2) inches, a B dimension of four (4) inches, a C dimension of ⅛ inch, and a D dimension in the range of seventeen and one-quarter inches to forty-two inches.
 4. A semi-rigid, elastomeric deflector as in claim 1, said deflector constructed of polycarbonate, and further comprising an A dimension of two inches, a B dimension of four inches, a C dimension of ¼ inch, and a D dimension of in the range of seventeen and one-quarter inches to forty-two inches.
 5. A semi-rigid, elastomeric deflector as in claim 1, said deflector constructed of polycarbonate, and further comprising an A dimension of two inches, a B dimension of four inches, a C dimension of ⅛ inch, and a D dimension of twenty-nine and one-half inches.
 6. A semi-rigid elastomeric deflector for re-directing the airflow produced by a Packaged Thermal Air Conditioner (PTAC), comprising a substantially longitudinal rectangular of length dimension A, a width dimension of B, and a thickness dimension of C, said panel bent at a straight line parallel to the lengthier sides of said panel, the bend forming an interior angle of one hundred forty degrees, and thereby defining two longitudinally-oriented rectangular sectors, being an upper sector having a windward face and a rear face, and an attaching sector having an upper surface and an inner surface; further comprising a first protective cover of plasticized material attached by means of a non-permanent adhesive, to both the windward face and the inner surface of said deflector and a second protective cover of plasticized material attached by means of a non-permanent adhesive, to both the rear face and the outer surface of said deflector and further, said attaching sector comprising a plurality of linearly-spaced pre-drilled holes arranged at varying intervals along the length of said attaching sector so as to provide for the securing of the attaching sector atop the front of the PTAC, said pre-drilled holes of a diameter permitting the insertion of specific multi-ribbed push-tab fasteners of a length enabling the insertion of said push-tab fasteners through said pre-drilled holes and continuing into corresponding apertures drilled in the top surface of any of a variety of specific brand-name PTAC's, said PTAC apertures drilled at intervals corresponding to the intervallic separation of the pre-drilled holes in the attaching sector of the deflector.
 7. A semi-rigid, elastomeric deflector as in claim 6, said deflector constructed of polycarbonate.
 8. A semi-rigid, elastomeric deflector as in claim 6, said deflector constructed of polycarbonate, and further comprising an A dimension of two (2) inches, a B dimension of four (4) inches, a C dimension of ⅛ inch, and a D dimension in the range of seventeen and one-quarter inches to forty-two inches.
 9. A semi-rigid, elastomeric deflector as in claim 6, said deflector constructed of polycarbonate, and further comprising an A dimension of two inches, a B dimension of four inches, a C dimension of ¼ inch, and a D dimension of in the range of seventeen and one-quarter inches to forty-two inches.
 10. A semi-rigid, elastomeric deflector as in claim 6, said deflector constructed of polycarbonate, and further comprising an A dimension of two inches, a B dimension of four inches, a C dimension of ⅛ inch, and a D dimension of twenty-nine and one-half inches.
 11. A method for (a) establishing energy savings and (b) the efficient distribution of warm or cool air emanating from the output grille or fins of any of a variety of Packaged Thermal Air Conditioners (PTAC) installed in a defined interior space, the method comprising the steps of: obtaining a primarily longitudinal rectangular panel constructed of semi-rigid polycarbonate material; bending said semi-rigid rectangular panel at a straight line parallel to the longitudinal sides of said panel to form an interior angle between one-hundred twenty and one-hundred fifty degrees, the bend thereby defining two longitudinally-oriented rectangular sectors, being an upper sector having a windward face and a rear face and an attaching sector having an upper surface and an inner surface; attaching, by means of a non-permanent adhesive, a first protective cover comprising a plasticized material having dimensions corresponding to the dimensions of said rectangular panel, to both the rear face and the outer surface of said panel; attaching, by means of a non-permanent adhesive, a second protective cover comprising a plasticized material having dimensions corresponding to the dimensions of said rectangular panel, to both the windward face and the inner surface of the panel; measuring, and marking in a linear orientation along the surface of the first protective cover, a plurality of locations for holes compatible with the configuration and profile of the front of the selected PTAC to which the panel will be attached; providing a plurality of multi-ribbed fasteners, comprising two sets of horizontally-oriented ribbed projections, the two sets of ribbed projections oriented perpendicularly to each other and integral to the stem of said fastener; drilling a plurality of holes into the pre-measured and marked locations on the surface of said first protective cover, the diameter of each of said holes corresponding to the stem diameter of specific multi-ribbed push-tab fasteners; removing the frame front of the selected PTAC; clamping the attaching sector of said panel to the uppermost surface of said front of the PTAC; drilling holes, using as a guide, the pre-drilled holes, through the front of the PTAC; releasing the clamps and subsequently peeling the plasticized covers from the deflector; re-aligning the deflector with the previous position abutting the front of the PTAC and thereupon, pushing a multi-ribbed fastener through each pre-drilled hole and on through the corresponding aperture on the front of the PTAC. 